Free cutting alloys



Patented Apr. 13, 1937 UNITED STATES.

PATENT \OFFICE Ohio,

America, Pittsburgh,

Pennsylvania assignors to Alumin um Company of Pa., a corporation of No Drawing. Application December 28, 1935,

Serial No. 56,549

Claims.

The invention relates to aluminum base alloys and is particularly concerned with aluminum base alloys containing magnesium, silicon, and copper.

5 Aluminum base alloys containing from about 0.1 per cent to 1.5 per cent of magnesium; and from about 0.5 per cent to about 2.5 per cent of silicon have heretofore been used. They are usually in the wrought condition since they are readily susceptible to mechanical deformation such as rolling, forging, or extrusion. It is possible, by appropriate thermal treatments to very substantially improve their physical properties. After a high temperature solution treatment they do not age-harden to any great extent at room temperature but may be artificially aged by temperatures somewhat in excess of room temperature as is well known in the art. For this reason these alloys may be wrought to substantially final form, then subjected to a high temperature solution treatment, and while in a relatively soft condition they may be given certain final working steps at low temperature. Since they do not materially age at room temperature these finishing steps may be performed at any convenient .time. They may ultimately be artificially aged if the maximum tensile strength, yield strength,

and hardness are desired.

The addition of from about 0.1 per cent to 1.0 138! cent of copper to the aluminum-magnesiumsilicon alloys above disclosed materially increases the tensile strength, yield strength, and hardness of the alloy in the heat treated condition. Such a copper addition, especially in the higher portion of the stated range, may cause a certain amount of room temperature age hardening, but this of course is not usually objectionable.

Since all commercial aluminum base alloys 40 contain some silicon as an impurity, usually less than, or not greatly in excess of 0.5 per cent, it is to be understood that the amount of silicon discussed herein, and hereinafter claimed, represents the total quantity of silicon present, and that the silicon content of the aluminum used should be known in order to provide a basis for determining the eventual composition of the aluminum-magnesium-silicon-copper alloy.

There are, however, some applications wherein aluminum-magnesium-silicon-copper alloys as hereinabove disclosed might be conveniently and profitably used except for an inherent disadvantage which militates against their use in the production of certain articles requiring exacting machining operations. Mechanical cutting operations such as drilling, shaping, or lathe-cutting are successfully carried out only by using certain precautions which increase the cost of production and perhaps favor the choice of another metal or alloy which can be machined more readily but which is not so desirable in other respects, as for example, in physical properties. When alloys are dimcult to machine this disadvantage becomes evident, in many cases, through rapid wear of the cutting tool edge, so that frequent tool re-sharpening is required. Despite continual lubrication the machined surface is rough and irregular, and the chip has a tendency to form a continuous curl or spiral which often fouls the tool or the mov-' ing parts of the machine. It is immediately apparent that there is need for an alloy of good working characteristics and satisfactory physical properties, yet possessing such favorable machining properties that the complete machining operations may be performed economically and successfully, and may be productive of a pleasing surface appearance.

Accordingly an object of our invention is the provision of an aluminum base alloy containing from about 0.1 to about 1.5 per cent of magnesium, from about 0.5 to 2.5 per cent silicon and from about 0.1 per cent to 2.0 per cent of copper, which may be readily and economically machined.

Our invention resides in the discovery that the foregoing object is effected by the addition of two or more of the elements lead, tin, thallium, cadmium or bismuth. The aluminummagnesium-silicon-copper alloys to which these elements are added in the proportions specified below, are known as free cutting or free machining alloys because they can be machined more rapidly than similar alloys without these elements and yet have as good or a better finished surface. After an extended series of investigations we have discovered that these five metals when added to aluminum-magnesium-silicon-copper alloys, form a class of alloying elements by reason of their favorable effect upon the machining properties of these alloys. In recognition of this effect we term lead, tin, thallium, cadmium and bismuth free machining elements. We have further discovered that the simultaneous presence of two or more of these elements is productive of an improvement in free machining characteristics which is considerably greater than that caused by the presence of the same total amount of a single free machining element. For example, the addition of 0.5 per cent of lead and 0.5 per cent of bismuth to an aluminum base alloy containing about 0.6 per cent of magnesium, 1.0 per cent of silicon and 1.0 per cent of copper, effects a greater improvement in machining quality than does the addition of 1.0 per cent of either lead or bismuth singly.

These five elements, we believe, are unique with respect to their effect on the machining characteristics of aluminum-magnesium-silicon-copper alloys. It is a fortunate circumstance, therefore, that they are also of relatively low melting point, a fact which makes possible their addition to molten aluminum in the pure state,.without the intervention of so-called rich alioys". As a matter of fact, we have observed that of all the metals whose melting point is lower than about 327 C., the melting point of lead, the five elements we have selected are the only ones which are commercially suitable and which impart free cutting characteristics but do not have an undesirable effect on the fundamental physical properties of the base alloy.

The total amount of free machining elements should not be less than about 0.05 per cent since below this amount there is scarcely any advantageous effect. We have determined that a maximum limit of about 6 per cent total of two or more of the free machining elements is suflicient for satisfactory commercial results, since although the free machining effect persists beyond this amount, certain of the other physical properties may be unfavorably aifected.

Aluminum magnesium silicon copper alloys containing two or more of the free machining elements, lead, tin, thallium, cadmium and bismuth may be machined more rapidly, with'less tool wear, less tool sharpening, better quality of chip and better machined surface than the same 40 base alloys without the free machining additions,

and in fact better than the same base alloys containing an equivalent total amount of a single free machining element.

As a preferred alloy within the range of the respective elements disclosed hereinabove we suggest an alloy containing about 0.6 per cent of magnesium, 1.0 per cent of silicon, 1.0 per cent of copper, and a total of 3 per cent of free machining elements, the balance being aluminum. For some applications which do not require a high degree of free machining quality, a lesser amount of the free machining constituents may be added to the alloy base, for instance 0.5 per cent lead and 0.5 per cent bismuth, or 0.5 per cent bismuth and 0.5 per cent cadmium.

For certain purposes, notably the improvement of tensile strength, hardness and grain structure, the alloys as hereinabove disclosed may be improved by the addition of one or more of the group of elements composed of molybdenum, vanadium, titanium, tungsten, zirconium, and chromium. From 0.05 to 1 per cent of any one of these elements may be used alone, but if more than one is employed the total amount should not 5 exceed about 2 per cent.

It is characteristic of the five elements, lead, tin, thallium, cadmium and bismuth that they form with aluminum a series of alloys of limited liquid solubility. We have reason to believe that 70 the free machining elements are the only ele-'- ments which exhibit this characteristic, with the possible exception of several metals which are not regarded as having any commercial promise as additions to aluminum base alloys. Within 75 the range disclosed and claimed-however the free machining elements may be added without unusual difllculty. We suspect that this characteristic feature of the disclosed elements may be one of the significant factors which contribute to their free machining effect. We believe that this effect is further strengthened by distributing the free machining constituent relatively homogeneously throughout the solid matrix, since these free machining constituents are also practically insoluble in the solid aluminum base.-

The free machining alloys which have been described hereinabove may be subjected to the thermal treatments well known in the art to improve their strength and hardness. We have found that a solution heat treatment and subsequent aging does not impair the free machining quality of the alloys and in many instances the treatment even tends to improve this property. For many purposes a relatively high strength and hardness are necessary to the successful performance of the machined article and hence the alloy must be heat treated. I This treatment is generally applied prior to the machining operation.

As hereinabove indicated the free machining elements, by reason of their low melting point, may be added to the molten aluminum in pure metallic form. However, since some difllculty may be encountered in introducing them in the higher percentages of our disclosed range we prefer to use the method which is more fully described in U. S. Patent No. 1,959,029, issued March 15, 1934. Briefly it involves heating the melt to a somewhat higher temperature than is customary, and vigorously stirring it in excess of a critical period of time.

The term aluminum as used herein and in the appended claims embraces the usual impurities found in aluminum ingot of commercial grade or picked up in the course of the ordinary handling operations incident to melting practice.

We claim: a

1. An aluminum base alloy consisting of about 0.6 per cent magnesium, 1.0 per cent silicon, 1.0 per cent copper, 0.5 per cent lead and 0.5 per cent bismuth, the balance being aluminum.

2. An aluminum base alloy consisting of about 0.6 per cent magnesium, 1.0 per cent silicon, 1.0 per cent copper, 0.5 per cent bismuth and 0.5 per cent cadmium, the balance being aluminum.

3. A free cutting alloy containing from 0.1 to 2 per cent of copper, from 0.5 to 2.5 per cent of silicon, from 0.1 to 1.5 per cent of magnesium,

and a total of from 0.05 to 6 per cent of at least two of the elements from the following metals, lead, tin, thallium, cadmium, and bismuth, to improve its machining properties, the balance being substantially aluminum.

4. A free cutting alloy containing from 0.1 to

2 per cent of copper, from 0.5 to 2.5 per cent of silicon, from 0.1 to 1.5 per cent of magnesium,

from 0.05 to 2 per cent of hardening metal from the group composed of molybdenum, vanadium, titanium, tungsten, zirconium and chromium, and a total of from 0.05 to 6 per cent of at least two of the elements from the following metals, lead, tin, thallium, cadmium, and bismuth, to improve its machining properties, the balance being substantially aluminum.

5. An aluminum base alloy consisting of about 1 per cent copper, 0.6 per cent magnesium, 1 per cent silicon, 0.5 per cent cadmium, and 0.5 per cent lead, the balance being aluminum.

LOUIS W. KEMPF.

WALTER A. DEAN. 

